Method and system for vaporization of a substance

ABSTRACT

A smoking device for generating and releasing smoking vapor free from contamination into the mouth of a user comprising a mouthpiece for providing vapor for inhalation to a user including a tubular casing containing a heater for heating a smoking substance at a substantially constant low temperature by regulating the flow of fuel by a thermal regulator and further having means for visual indication of the operation of the device.

This application claims the benefit of my Provisional Patent ApplicationNo. 60/700,105 filed on Jul. 19, 2005, which is hereby incorporated byreference herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is directed to improvements in smoking devices,particularly to smoking articles which employ a formed tobacco cartridgeas a source of producing vapor by heat transfer to the cartridge byconduction, convection, and radiation for smoke and flavor. The presentinvention relates to self-contained vaporization devices, and moreparticularly, to a low-temperature vaporization device for use oftobacco product. The device is of an elongated main body with amouthpiece at one end and an attached tubular casing at the other endhaving a vaporization chamber and a heater. The mouthpiece and thecasing form an unitary unit.

2. Description of the Related Art

Smoking devices, such as cigarette holders and pipes are well known inthe art for providing flavored vapor from a smokable substance to a userfor therapeutic and smoking pleasure. However, existing devices usedhave no control of heating and combustion of the tobacco products. Thedevices tend to produce toxic, tarry and carcinogenic by-products whichare harmful and also impart a bitter and burnt taste to a mouth of auser.

A further problem is that there is no control of contamination of theinhaled vapor mixture with heater exhaust gases, due to inappropriateproportioning and location of the inlets and the exhaust vents.Typically, the exhaust gas is used to directly heat the tobacco, andthose gases contain harmful byproducts of incomplete combustion.

In an effort to overcome these deficiencies, there have been numerousattempts to provide a device structure and the substance for producingvapor for smoking which is free from harmful by-product and wouldprovide a cool and soothing vapor for smoking.

For example, U.S. patent application Ser. No. 2004/0237974 A1, publishedon Dec. 2, 2004 for Min discloses a filtering cigarette and cigar holderwhich removes tar and nicotine from the tobacco smoke.

U.S. patent application Ser. No. 2004/0031495 A1, published on Feb. 19,2004 for Steinberg discloses a vaporization pipe with flame filter whichuses a flame to vaporize the smoking substance.

U.S. Pat. No. 6,164,287, issued Dec. 26, 2000 to White, describes asmoking device which produces smoke from tobacco at low temperatures,without producing harmful byproducts.

U.S. Pat. No. 4,848,374, issued Jul. 18, 1989 to Chard et al describe asmoking device to vaporize aerosol precursor, an event which precedescondensation to mainstream aerosol precursor by contact with heatedsurface rather than by hot gases into the mouth of a smoker.

U.S. Pat. No. 4,219,032, issued Aug. 26, 1980 to Tabatznik et aldescribe a smoking device wherein an extracted smoke is cooled bypassing it through a suitable liquid to provide a soothing smoke.

U.S. Pat. No. 4,020,853, issued May 3, 1977 to Nuttall, describes asmoking pipe made of ceramic material such as colored and ornamentalporcelain for enhancing the artistic look, and also to provide acirculating air to keep the outer wall of the pipe cool and safe forhandling.

U.S. Pat. No. 3,792,704, issued Feb. 19, 1974 to Parker, describes apipe tobacco smoking system, wherein the pipe and the tobacco capsuleare mutually designed to yield a slim-line smoking combination that canbe manufactured from relatively low temperature thermoplastic material.

SUMMARY OF THE INVENTION

The present invention is drawn to a novel smoking device consisting of amouthpiece and a casing having a heater, a low temperature vaporizationchamber, a fuel tank, an igniter with control means for maintainingequilibrium point by keeping the operating temperature below 400 F,preferably below 350 F during combustion whereby in order to maintain astable operating temperature, a thermal regulator is used to controlflow rate of the fuel.

Accordingly, it is principal object of the invention to provide amouthpiece made of a high temperature food-safe material, such asceramic, glass, or high temperature plastics known as PEI resin (brandname Ultem) However, suitable plastic or wood, etc., could also be usedbut would additionally require an insulating material that would preventexcessive heat reaching the user's lips.

Additionally, air inlets are directed downwards, so that fresh ambientair drawn through mixes with the vapor generated into the vaporizationchamber located above the smokable substance cartridge, which isextracted from the cartridge by inlets located below the cartridge anddrawn into user's mouth for inhalation.

It is another object of the invention to provide air inlet or inletshaving a diameter and direction sized to admit ambient air into thechamber to heat up the substance and not effect the operatingtemperature and also regulating the velocity of ambient air entering andmixing with the vapor generated from combustion, radiation andconvection in the chamber at such a rate that the proportionateinhalation passage provides a perception to the user as if the smoke isdrawn through a cigarette.

It is still another object of the invention to provide a heater which isseparated from the vapor chamber by an insulating medium such as ringmade of PTFE, ceramic or other insulating material and therebypreventing the exhaust gases produced by the heater from entering andcontaminating the vapor in the vaporization chamber collected forinhalation.

Another object of the invention to provide a heater is formed of aconductive shell and a catalyst, the shell may be of one or morematerial formed by welding or pressing together. Whereas, the catalystcould be of platinum or palladium impregnated metal or glass or othersuitable material, which provides for efficient flameless combustion ofthe fuel and glows red when heated to indicate that the device isactivated. Additionally, a feedback loop could be employed to regulatethe desired temperature.

Preferably the tobacco cartridge formed and shaped for easier insertioninto the heating chamber and to snugly fit into the cavity of theheating chamber for improved thermal conduction and vaporization. Thecartridges are formed and wrapped into wrapper which does not producesignificant amount of harmful gases.

These and other objects of the present invention will become readilyapparent upon further review of the following specifications anddrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a portable vaporization device, according to apreferred embodiment of the present invention.

FIG. 2 is a sectional view of the same embodiment.

FIG. 3 is a perspective view of a heater, according to the sameembodiment.

FIG. 4 is a cutaway view of an alternate embodiment according to thepresent invention.

FIG. 5 is a sectional detail view of a tobacco cartridge, according tothe preferred embodiment.

FIG. 6 is a perspective view of a tobacco cartridge, according to thepreferred embodiment.

FIG. 7 is a sectional detail view of a tobacco cartridge, according toan alternate embodiment.

FIG. 8 is a sectional detail view of a tobacco cartridge, according toan alternate embodiment.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1 and FIG. 2, the exterior of the device 10 comprisesa mouthpiece 11, a tubular case 12, and the base 14 of a butane tank 21.The mouthpiece is removable and creates an airtight seal with theinterior of the case. With the mouthpiece removed, a tobacco cartridge(FIG. 5) is introduced to vaporization chamber 15 of a heater 16. Themouthpiece is then reinserted to close the device.

The mouthpiece is made of a high-temperature and food-safe material suchas ceramic, glass, or various high-temperature plastics such as PEIresin (brand name Ultem). Design is simplified by use of hightemperature materials, but standard plastics or wood, etc, could also beused with the addition of an insulating component that prevents anyexcessive heat from reaching the user's lips.

To activate the device, the butane tank is pulled axially outward,partially removing it from the case. This starts the flow of butane byopening a master valve 18, and then activating a piezoelectric igniter13. The tank remains in the partially removed position for the durationof use. While the master valve is open, butane flows through a thermalregulator 17, and into the carburetor 20. Ambient air enters the casethrough slot 19. A venturi in the carburetor entrains air, causing it tomix with the butane. The mixture then flows into the heater 16.

The lead of the ignitor is positioned in the heater. With the spark ofthe ignitor (immediately following the start of gas flow) the gasignites and heat starts conducting throughout the heater. Heat transfersto the cartridge by conduction, convection, and radiation. The cartridgeis shaped to fill the chamber, so as to maximize surface contact forthermal conduction.

As the cartridge heats, vapor generates within the cartridge and in thespace immediately above it. When a user draws on the device, fresh airenters through air inlet 22, mixes with the vapor, and the mixture isdelivered to the user via the inhalation passage 23. In the preferredembodiment, the air inlet or inlets are directed downward, so as toimprove the extraction of vapor from the cartridge. They could also bedirected along a diagonal through the mouthpiece, or laterally throughthe case itself, above the cartridge.

FIG. 3 depicts a detailed view of the heater 16. The heater comprises athermally conductive shell 26 and catalyst 27. The shell could becomprised of one material, or a combination of materials welded orpressed together. The catalyst could be platinum- orpalladium-impregnated metal or glass, or other suitable material knownto those skilled in the art. The catalyst provides for efficientflame-less combustion of the butane. The vent 28 of the heater ispositioned such that it is visible through the slot 29 of the body asshown in FIG. 1. This allows the user to see the catalyst which, whenheated, can glow red to indicate that the device has been activated.

Referring again to FIG. 3, adjacent to the heater and in intimatethermal contact is the thermal regulator 17. As the temperature of theheater increases, so does that of the regulator. The regulator isdesigned to restrict the flow of butane as the temperature increases,thus creating a feedback loop. In the preferred embodiment, theregulator consists of a bimetallic strip 60 and silicone tubing 61 whichis the conduit of the butane. The two are arranged such that as thebimetallic strip heats up, it curls to pinch the silicone tube andthereby restrict the flow of butane. The reduced flow of butane resultsin less heat generated. The heater subsequently cools down, and so doesthe regulator, allowing more butane to flow again. The overall result isthat a stable operating temperature is established in the heater. Such asystem can be readily tuned to achieve an operating temperature thatvaries by less than +1-5 degrees Fahrenheit.

The regulator further comprises a moveable backplate 62 which allowsadjustability of the operating temperature by adjusting the temperatureat which the bimetallic actuator closes the tube valve. This is to beperformed once at manufacture, to calibrate the device. In alternateembodiments, a control means could be used to allow the targettemperature of the device changed during operation.

In the preferred embodiment, the regulator comprises in part abimetallic strip and silicone tubing valve. In alternate embodiments,the regulator could be comprised of other materials and configurations,as described later.

For the purposes of vaporizing most botanicals in this device, thedesired operating temperature is below 400 F; preferably below 350 F.

In the preferred embodiment, the air inlet diameter is sized such thatinhalation is somewhat inhibited. This allows time for ambient airentering the chamber to heat up and not affect operating temperatureconsiderably. It also increases velocity of the entering air, whichimproves circulation and mixing in the vaporization chamber. It alsocreates a partial vacuum, lowering the vapor point temperature formaterial contained in the vaporization chamber. The reduction in drawrate can also serve to give the impression of drawing on a cigarette orpipe. Both the fresh air inlet and inhalation passage can be adjusted toprovide appropriate draw rate for the operating temperature of thedevice, and the perception intended for the user.

Once the cartridge is consumed, the device is turned off by pushing thetank back into the case, closing the master valve. The spent tobaccocartridge is removed by opening the device and turning the body over. Inthe preferred embodiment, the cartridge simply falls out. In alternateembodiments, a mechanism could be used to quickly and easily remove thecartridge. This mechanism could include, but does not require, the useof a pin or slide part to eject the cartridge as another part of thedevice is moved or removed. The removal mechanism could also involveintroduction of a foreign object.

In an alternate embodiment, the mouthpiece is permanently attached tothe body. In that case, the vaporization chamber could be accessed byoperating a sliding or hinged door, or similar means, built into thedevice.

The heater of the device is fitted into the case with an insulator 24.The insulator could be made of PEI (brand name Ultem), ceramic, or otherinsulating material. The insulator serves to minimize thermal transferfrom the heater to the case, while creating an air-tight seal. The sealprevents exhaust gases produced by the heater from entering thevaporization chamber. Exhaust gases are instead vented out the caseslots. Since the air inlet is distant from the slots, there issubstantially no contamination of the inhaled vapor mixture by heaterexhaust gases.

In an alternate embodiment, the insulator could be a partially hollowshell, containing a sealed vacuum. In another embodiment, the heatermight be sealed directly to the case by braising in a vacuum furnace, soas to create a vacuum between the two and obviate need for an insulatorcomponent.

In the preferred embodiment, the tank is made of a translucent material.This allows the user to determine the level of fuel remaining by lookingat the base of the tank.

In the preferred embodiment, the case is made of a material that iseither a good thermal conductor (such as aluminum), or a poor one (suchas ceramics). In both cases, the effect is that the body remains coolenough to touch over a large portion of its surface.

In the preferred embodiment, a bimetallic actuator is used in theregulator. In alternate embodiments, a shape memory alloy actuator suchnickel-titanium alloys (“Nitinol”) could be used. Alternatively, aparaffin-filled component that expands and contracts to modulate butaneflow could be employed. Alternatively, a system could be employed tomeasure the current temperature, e.g., with a thermocouple sensor andcompare it to a prescribed temperature, e.g., with a micro-controller,and by controlling an electromechanical valve, e.g., servo or solenoidvalve. In an embodiment with user-selected temperature, as describedabove, the selected temperature could be used as an input to thissystem.

In the preferred embodiment, a thermal regulator is used. In analternate embodiment, the device is constructed without an activeregulating element. This could result in reduced complexity and inlowering the overall cost of the device. In this case, the flow ofbutane is set at a low level. In use, the temperature inside the chamberincreases until an equilibrium point where additional heat introducedequals the heat lost to the environment. Heat is lost by conductionthrough the body of the device, and with the vapor delivered to theuser. This equilibrium point determines the operating temperature of thedevice. By changing the butane flow rate, size and material of theburner, and other factors, the system can be calibrated to provide afairly stable desired operating temperature.

The principal advantage of the preferred bimetallic regulator feedbackloop methods over the equilibrium method is that the operatingtemperature is not dependent on environmental factors such as ambienttemperature and wind.

In the preferred embodiment, a piezo-electric ignitor is used. Otherignitors could be used, such as, a flint starter or battery-poweredresistive coil.

In the preferred embodiment, the butane tank is meant to be refillable,and has a port 25 for that purpose. As an alternate embodiment, the tankmight be disposable once its fuel is exhausted. A release mechanism suchas a pin or cam would be employed allowing the user to quickly removethe depleted tank and replace it with a full one. The replaceable tankmight include additional parts of the device including, but not limitedto, the ignitor and heater. Butane is the preferred fuel source, butcould be replaced by other liquid fuels, such as ethanol.

In alternate embodiments of the present invention, various means offeedback could be used to indicate the following states or metrics ofthe device: 1) the device is on, 2) the current temperature of thevaporization chamber, 3) the chamber is below a prescribed operatingtemperature, 4) the chamber has reached a prescribed operatingtemperature and vapor is ready for consumption, and 5) the chamber hasexceeded a prescribed operating temperature.

The means of the feedback includes both physical and electronicimplementations. Possibilities include thermochromatic paint,light-emitting diodes and liquid crystal display. The sensing andcontrol means for electronic feedback could be implemented by use ofthermocouple and micro-controller, as is known to those skilled in theart.

Active elements contained in botanicals vaporize at differenttemperatures. In the preferred embodiment, the device is calibrated toestablish a single stable temperature, intended for vaporizing solelytobacco or solely chamomile, for example. In alternate embodiments, acontrol means would be used to select a variety of temperature settings.The user would choose which setting based on the type of cartridge used.The control means could effect a desired temperature mechanically, suchas by changing flow rate of the valve, or electronically, such as byelectromechanical valve and micro-controller intermediary.

Butane was found to be the most energy-dense and practical fuel source.In alternate embodiments of the invention, the butane heating system isreplaced by a battery-powered electric heater or other compact heatsource.

FIG. 4 depicts a cutaway view of an alternate embodiment which moreclosely resembles a traditional pipe form. In this embodiment the deviceretains all of the critical elements from the preferred embodiment. Theuser inserts a tobacco cartridge 40, under a sliding top piece 41, wherethe cartridge mates with the heater 42. Fuel held in the tank 43 isreleased by turning dial 44 to open master valve 45. The fuel travelsthrough the regulator 51, and then through the carburetor 46 where itdraws in air through the intake port 47 and catalyzes in a mannersimilar to that of the preferred embodiment. As the cartridge 40 reachesits operating temperature the user places the mouthpiece 48 in theirmouth and draws air in through the inhalation intake port 49 and throughthe vapor passage 50 where it is pre-cooled.

FIG. 5 depicts a sectional view of the tobacco cartridge 30. In thepreferred embodiment, it consists of tobacco material 31, enclosed in awrapper 32, with perforations 33, and aeration wells 34. The wrappedcartridge allows for the easy insertion and disposal of tobacco materialwithout creating a mess, while the perforations allow the formed vaporto be released. When the cartridge is used up it can be easily disposedof in its entirety.

Here, tobacco or tobacco material is defined as any combination ofnatural and synthetic material that can be vaporized for pleasure ormedicinal use. As an example, one test cartridge was prepared asembodiment of the present invention using flue-cured tobacco, glycerin,and flavorings. Those skilled in the art of tobacco product manufactureare familiar with these and other ingredients used for cigarettes,cigars, and the like. The test cartridge was produced by choppingtobacco into fine pieces (less than 3 mm diameter, preferably less than2 mm), adding the other ingredients, and mixing until even consistencywas achieved.

In the preferred embodiment, the cartridge is primarily cylindrical. Inother embodiments, the form could be modified for various reasons. As anexample, the walls of the cartridge might be drafted for easierinsertion into the vaporization chamber. Or, the bottom of the cartridgemight possess receptacles, which when combined with complimentaryfeatures on the surface cavity of the vaporization chamber would allowfor more surface contact and hence improved thermal conduction.

Any material could be used for the wrapper, provided that when heated tothe operating temperature, it does not produce significant amounts ofharmful gases. Aluminum foil and parchment paper are two examples. Withpapers, the cartridge would be manufactured in a folded-cup design,similar to that shown in FIG. 6. With films or metal foils, the wrappercould be pressed or blow-molded to the appropriate shape.

During manufacture of the preferred embodiment, the cartridge isenclosed on all sides, and perforated on the top so that vapors canemanate upwards. In the perforation step, or in an additional step, theoptional aeration wells would be created.

In an alternate embodiment, the cartridge might be wrapped on all sidesbut leaving the top exposed, as shown in FIG. 7. This is possible sincethe purpose of the wrapper is primarily to prevent tobacco material fromtouching the sides and bottom of the vaporization chamber.

In another embodiment, the material for the top of the cartridge mightbe vapor-permeable, such that perforations are not necessary.

In another embodiment, the cartridge as purchased by the user has noopenings, but is punctured prior to insertion into the device, or uponintroduction to the vaporization device. The latter could be achieved byadding a hollow puncturing means to the mouthpiece part of the device.For example, the inhalation passage of the mouthpiece could be extendedby a hollow tube. When the mouthpiece is reinserted to close the device,it pierces the cartridge previously introduced, and allows a path forvapor to exit to the user.

In the preferred embodiment, the tobacco material is a homogenousmixture. In another embodiment, there might be two layers, as shown inFIG. 8. The moist layer 35 has higher content of vapor-forming materialthan the dry layer 36, which consists of dry tobacco or other materialacting as a filter. The dry layer serves to prevent any liquid frombubbling up and out of the cartridge during heating.

In another embodiment of the cartridge, a lower compartment mightconsist entirely of a vapor-forming medium, such as glycerine. An upperregion would consist of the tobacco material to be vaporized, and thetwo would be separated by a material that only allows the medium to passin a vapor or gaseous phase. Gore-tex (brand name) is one such material.In use, vapor generated in the lower region would pass through thesemi-permeable membrane, volatize the active components of the tobacco,and a mix of the two would be delivered to the user upon inhalation.

In another embodiment, the consistency of the tobacco material is suchthat the wrapper is not necessary. This is possible if at least theouter surface of the cartridge is dry and cohesive enough to not leavedeposits inside the device. Such a cartridge can be made by formingtobacco material in a mold. If the resulting surface is excessivelymoist, it can be dried by heating the cartridge in an oven.

It is to be understood that the present invention is not limited to theembodiments described above, but encompasses any and all embodimentswithin the scope of the following claims.

What is claimed is:
 1. A cartridge for use in a smoking devicecomprising: a wrapper containing a smokeable material comprising a vaporforming medium and fine pieces of tobacco material wherein all of thefine pieces of tobacco have a diameter of less than 3 mm; and at leastone perforation in the top of the wrapper, through which at least oneaeration well is created in the tobacco, wherein tobacco is arrangedbetween a bottom of the aeration well and a bottom of the cartridge, andwherein the at least one perforation allows an exit of an inhalablevapor generated from heating, without burning, the smokeable material.2. The cartridge of claim 1, wherein the wrapper comprises aluminum. 3.The cartridge of claim 1, wherein the smokeable material vaporizes whenheated to a temperature required to vaporize the smokeable material. 4.The cartridge of claim 3, wherein the temperature is below 400 F.
 5. Thecartridge of claim 3, wherein the cartridge is configured to be insertedinto a device wherein the device is capable of vaporizing the smokeablematerial.
 6. The cartridge of claim 5, wherein the cartridge isconfigured to be inserted into a vaporization chamber of the device. 7.The cartridge of claim 5, wherein the vapor forming medium comprisesglycerine.
 8. The cartridge of claim 1, wherein the smokeable materialis moist.
 9. A cartridge for use in a smoking device comprising: awrapper containing a smokeable material comprising a vapor formingmedium and fine pieces of tobacco material wherein all of the finepieces of tobacco have a diameter of less than 3 mm; and at least oneperforation in the top of the wrapper, through which at least oneaeration well is created in the tobacco, wherein tobacco is arrangedbetween a bottom of the aeration well and a bottom of the cartridge, andwherein the at least one perforation allows an exit of an inhalablevapor generated from heating, without burning, the smokeable material,and wherein the cartridge is enclosed on all surfaces except the onesurface with the at least one perforation.
 10. A cartridge for use in asmoking device comprising: a wrapper containing a smokeable materialcomprising a vapor forming medium and fine pieces of tobacco materialwherein all of the fine pieces of tobacco have a diameter of less than 3mm; and at least one aeration well in the tobacco material that extendsfrom a top of the wrapper, wherein tobacco is arranged between a bottomof the aeration well and a bottom of the cartridge, and wherein theaeration well is aligned with a perforation to be made in the top of thewrapper in order to provide aeration of an inhalable vapor generatedfrom heating, without burning, the smokeable material.